ICM/ICAD Motorized Valve

Installation, Programming, and Trouble-shooting

REFRIGERATION &
AIR-CONDITIONING

Quick Start Guide

ICM/ICAD Motorized Valve

Installation, Programming, and Troubleshooting

Contents

Page
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Wiring the ICAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ICAD Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ICAD Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Troubleshooting
The Manual Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Service parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Common questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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ICM/ICAD Motorized Valve

Installation, Programming, and Troubleshooting

Installation

1. The ICM valve and ICAD motor actuator must be installed in horizontal pipelines with the
motor actuator pointing upwards.
2. To prevent damage to O-rings and the valve seat, remove the one-piece ICM bonnet and
function module from the valve body prior to welding the valve body in the line. For ICM
20 (3/4 size) the valve seat is not integrated with the valve bonnet and must be
separately removed from the valve body with a 12 mm hex key prior to welding
(see diagrams below).

Removing ICM 25 to 65 bonnets

1) Remove the 4 bolts
2) Rotate the bonnet as shown
3) Pry the bonnet out of the valve body
by using screw drivers between the
bonnet and valve body as shown

1
2

No.

3
2c

Danfoss (USCO / MKS), 11 - 2006

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Part description

ICM body (housing)

ICM bonnet/function module

2a

O-ring for bonnet/function

module

2b

O-ring for bonnet/function

module

2c

O-ring for sealing ICAD motor

with ICM valve

ICM adapter/valve stem

ICM bonnet gasket

Bolts for ICM

11

ICAD motor actuator

12

O-ring for ICM 20 seat orifice

13

ICAD screws

14

Guide ring

15

ICM 20 valve seat orifice

ICM/ICAD Motorized Valve

Installation, Programming, and Troubleshooting

Care should be taken to protect the ICM function module while it is removed from the
valve body.
3. Weld the valve body in line making sure the arrow on the valve body is pointing in
the direction of flow.
4. Remove all debris from the valve body before re-installing the bonnet.
5. Install the bonnet/function module into the valve body.
a. For ICM 20, make sure that the removable orifice seat is installed in the valve body
with the small O-ring between the orifice seat and body. Make sure the bonnet gasket
is installed and in good condition.
b. For ICM 25 through ICM 65, check that the two O-rings on the bonnet and gasket
located between the bonnet and valve body are installed and in good condition. A
light coating of refrigerant oil on the bonnet O-rings will facilitate installation of the
bonnet.
6. Install the four bolts and torque to the following specifications:
Valve body

Nm

ft lbs

ICM 20

50

37

ICM 25

80

59

ICM 32

80

59

ICM 40

90

66

ICM 50

100

74

ICM 65

110

81

7. Install the ICAD motor actuator on the ICM valve:

a. The ICM valve must not be in its fully opened position while the ICAD motor is
calibrated with the valve at a later step. Therefore, if the opening degree of the ICM
valve was changed from the factory setting, it should be set to an opening degree
between 0% and 75% using the manual magnet tool. To easily ensure correct
positioning, turn the manual tool counter-clockwise until it is clear that it cannot be
turned further.
b. Make sure that the ICM adapter/valve stem and inner ICAD motor magnets are
completely dry and free from any debris.
c. For applications below freezing, the ICM adapter O-ring (position 2c in the diagram
on page 3) must be removed, and Molycote G 4500 grease (supplied with ICAD
motor) needs to be applied in the O-ring groove on the adapter and on the O-ring
before it is re-installed on the ICM adapter. The Molycote grease ensures a good seal
between the ICAD motor and the ICM adapter to prevent moisture from entering the
ICAD magnets.
d. Place the ICAD motor on the valve stem.
e. Push the ICAD motor completely down to the identification ring on the valve stem
and use a 2.5 mm hex key to tighten the set screws evenly so the ICAD motor is
centered on the ICM adapter (torque: 3 Nm/ 2.5 lb-ft).

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ICM/ICAD Motorized Valve

Installation, Programming, and Troubleshooting

Wiring the ICAD

Note: The ICAD is powered by a 24 Volt DC power source.

There are two cables pre-mounted and connected to the ICAD motor actuator. Never try to
open the ICAD motor because the special moisture seal will be damaged.
The power cable consists of 3 wires:
Green: () common (ground)
Brown: (+) positive from 24VDC power source
White: (+) positive from UPS/battery backup (optional)
The control cable consists of 7 wires:
Yellow: () common (ground)
Gray: (+) positive 4-20mA or 0-20mA input to control ICAD motor
Blue: (+) positive 4-20mA or 0-20mA output from ICAD for valve
position feedback
Pink: (+) positive 2-10V or 0-10V input to control ICAD motor. Also used as a
digital input with the yellow wire for on/off solenoid valve operation.
White: common alarm (digital NPN transistor output when combined with
yellow wire)
Brown: indicates ICM is fully open (digital NPN transistor output when combined
with yellow wire)
Green: indicates ICM is fully closed (digital NPN transistor output when combined
with yellow wire)

Electrical Data
Supply voltage is galvanically isolated from input and output wires.
Supply voltage
24 V d.c., +10% / -15%
Load ICAD 600: 1.2 A

ICAD 900: 2.0 A
Fail safe supply
Min. 19 V d.c.
Load ICAD 600: 1.2 A

ICAD 900: 2.0 A
Anolog input - Current or Voltage
Current
0/4 - 20 mA
Load: 200 W
Voltage
0/2 - 10 V d.c.
Load: 10 kW
Analog output
0/4 - 20 mA
Load: 250 W
Digital input - Digital ON/OFF input by means of voltfree contact (Signal/Telecom relays with
gold-plated contacts recommended) Voltage input used
ON: contact impedance < 50 W)
OFF: contact impedance > 100 kW
Digital output - 3 pcs. NPN transistor output
External supply: 5 - 24 V d.c. (same supply as for ICAD can be used, but please note that the
galvanically isolated system will then be spoiled).
Output load: 50 W
Load:
Max. 50 mA

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ICM/ICAD Motorized Valve

Wiring diagram showing ICAD wired with

a PLC or other type of third-party
electronics

Installation, Programming, and Troubleshooting

Terminal box is customer supplied.

PLC
+ Active 4-20 mA PLC output to control ICAD

Note:
The ICAD supplies the power for the 4-20 mA
feedback signal.

Gray

Active 4-20 mA PLC output to control ICAD

Yellow

Passive 4-20 mA PLC input

for valve position feedback

Blue

+ Passive 4-20 mA PLC input

White
Brown
Green

for valve position feedback

Optional UPS/battery back up

+
-

24 V d.c
Power
Supply

CUSTOMER SUPPLIED

Wiring diagram with Danfoss EKC

controllers

Terminal box is customer supplied.

Note:
For instructions on completely wiring an EKC
controller, please see the relevant EKC
controller manual.
Yellow (ground)
Gray (+ 4-20 mA)
Blue (+ 4-20 mA)

Optional position
feedback
Only possible
with EKC 347

White
Brown
Green

Optional UPS/battery back up

+
-

24 V d.c
Power
Supply

CUSTOMER SUPPLIED

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Danfoss (USCO / MKS), 11- 2006

ICM/ICAD Motorized Valve

Wiring diagram showing ICAD wired with

a digital input for ON/OFF solenoid valve
operation

Installation, Programming, and Troubleshooting

Terminal box is customer supplied.

Pink

Note:
The ICAD motor can be programmed to
open or close when the relay is closed.
See parameter 09 in programming
section.

Relay

Yellow

White
Brown
Green

+ Optional UPS/battery

back up

+
-

24 V d.c
Power
Supply

CUSTOMER SUPPLIED

Wiring diagram showing ICAD digital

outputs wired with customer supplied
auxiliary relays

Terminal Box
Terminal
box is customer supplied.

Auxillary relays

Note:
The same 24 Vd.c. power supply that
powers the ICAD can be used with the
ICAD digital outputs to power auxiliary
relays (or other small load devices), but
please note that the system will no
longer be galvanically isolated.

+ 5-24 V d.c
- Power

K1 K2 K3

Supply

White
Brown
Green
Yellow

White
Brown
Green

K1

K2

Optional UPS/

K3

+ battery back up

K1 : Common Alarm
K2 : ICM fully open
K3 : ICM fully closed

+
-

24 V d.c
Power
Supply

CUSTOMER SUPPLIED

Danfoss (USCO / MKS), 11 - 2006

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ICM/ICAD Motorized Valve

Installation, Programming, and Troubleshooting

ICAD Overview

Before programming it is important to understand the functionality of the ICAD actuator:

1. The ICAD is a digital stepper motor. As such, it will count steps up and down from the
position it believes it is in. Every time, the ICAD is powered on, it will drive itself to the
closed position in order to re-establish its base point of reference. It will then move back
to the position corresponding to the signal it is receiving from the control wiring.
2. The ICAD can be put into manual mode to move it (using the up and arrows) to a location
different from the location that the signal is telling it to be in (see parameter 01, p. 6).
When in the manual mode, the display screen will be flashing and will continue to flash
flashing the % opening of the valve until the ICAD is taken out of the manual mode.
3. The ICAD can be operated in analog mode (for modulating operation) or in digital mode
for solenoid operation. The ICAD can receive a variety of control signals (see parameter
03, p. 6) and can send a valve position output signal to modulate another ICAD or to a PC
or PLC for monitoring. (see parameter 06, p. 6)
4. Because the ICAD is employs a digital stepper motor, its speed can be adjusted to any
percentage of full speed through the parameter menu. (see parameter 04, p. 6)
5. The ICAD can be connected to a 24 VDC UPS (Uninterruptible Power Supply) and can be
programmed for actions when the normal power has been cut and the ICAD is operating
off of the UPS power. (see parameter 07 and 12 , p. 6)

Operating the ICAD Menu

1. In order to access the menu,

PRESS and HOLD the middle button (2) until the menu screen appears.

1.
2.
3.
4.

Down arrow push button

Enter
Up arrow push button
Display

2.

3.

Once you are in the menu, use the up (3) and down (1) arrow keys to move through the
list of parameters.
To display the current setting of a parameter press the middle button.
a. To change the value of a parameter setting, use the up or down arrow to establish
the new setting while in that particular parameters display mode.
b. Once the new setting for a parameter has been selected, push the center button to
save the charge and return to the menu.
4. Repeat this procedure for all parameters.
5. Exit from the parameter list by pressing and holding the middle button for 2 seconds.
The ICAD will automatically exit if no buttons are pushed for 20 seconds.

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Danfoss (USCO / MKS), 11- 2006

ICM/ICAD Motorized Valve

Installation, Programming, and Troubleshooting

Programming the ICAD

When the ICAD motor is first powered, the ICAD display will flash an A1 alarm. This means
that the ICM valve size that is being used with the ICAD motor needs to be selected in
parameter 26. Parameter 26 is password protected and will not appear in the parameter list
until the user enters the password in parameter 10. The password is 11, and will allow the
user to access parameter 26 where the appropriate valve size is selected. When the ICM
valve size is selected, the ICAD will calibrate itself to the ICM valve and will then be ready for
control by a 4-20mA signal. For most applications, this is the only programming that will
need to be done if the ICAD is going to be controlled by a 4-20mA input.

ICAD Parameters
Display
name

Min.

Max.

Factory
setting

Unit

100

ICM valve Opening Degree is displayed during normal operation.

Running display value (see 01, 05).

Main Switch

01

Internal main switch

1: Normal operation
2: Manual operation. Valve Opening Degree will be flashing. With the down arrow
and the up arrow push buttons the OD can be entered manually.

Mode

02

Operation mode
1: Modulating ICM positioning according to Analog Input (see 03)
2: ON/OFF - operating the ICM valve like an ON/OFF solenoid valve controlled via
Digital Input. See also 09.

Type of Analog Input signal from external controller

1: 0 - 20 mA
2: 4 - 20 mA
3: 0 - 10 V
4: 2 - 10 V

Speed can be decreased. Max. speed is 100 %

Not active when 01 = 2
If 02 = 2 the display will indicate speed in display. Low, Med and High also
means ON/OFF operation.
If 04 < = 33,
Low is displayed
33 < If 04 < = 66, Med is displayed
If 04 > = 67
High is displayed

Not active before 26 has been operated.

Always auto reset to 0.
CA will flash in the display during calibration, if Enter push button has been
activated for two seconds.

Type of A0 signal for ICM valve position

0: No signal
1: 0 - 20 mA
2: 4 - 20 mA

Define condition at power cut when fail safe is installed.

1: Close valve
2: Open valve
3: Maintain valve position
4: Go to OD given by 12

Description
ICM OD (Opening
Degree)

Analog Input signal

Speed at ON/OFF and

Modulating Mode

Automatic calibration

Analog Output signal

03

04

05

06

100

100

Comments

Fail safe

07

Digital Input function

09

Password

10

199

Enter number to access password protected parameters: 26

Password = 11

Old Alarms

11

A1

A99

Old alarms will be listed with the latest shown first. Alarm list can be reset by
means of activating down arrow and up arrow at the same time for 2 seconds.

OD at powercut

12

100

50

Only active if 07 = 4
If fail safe supply is connected and powercut occurs ICM will go to entered OD.

ICM configuration

Danfoss (USCO / MKS), 11 - 2006

26

Define function when DI is ON (short circuited DI terminals) when 02 = 2

1: Open ICM valve (DI = OFF = > Close ICM valve)
2: Close ICM valve (DI = OFF = > Open ICM valve)

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NB: Password protected. Password = 11

At first start up A1 will flash in display. Enter valve type
0: No valve selected. Alarm A1 will become active.
1: ICM20 with ICAD 600
2: ICM25 with ICAD 600
3: ICM32 with ICAD 600
4: ICM40 with ICAD 900
5: ICM50 with ICAD 900
6: ICM65 with ICAD 900

ICM/ICAD Motorized Valve

Installation, Programming, and Troubleshooting

Troubleshooting

The manual tool should always be ordered with any ICM/ICAD assembly. This tool gives the
user the ability to remove the ICAD actuator and manually rotate the valve in the open or
close direction depending on need and application. When using the manual tool, a clockwise rotation will open the valve and a counter-clockwise rotation will close the valve.

The Manual Tool

NOTE:
It is very important to remember that when rotating the valve manually you are changing
the position from that in the actuators memory. If power is removed from the actuator prior
to using the manual tool, no problem will occur because, once the ICAD is powered up again,
it will automatically recalibrate to the fully closed position before returning to the position in
memory to which the control signal last set the valve. This recalibration will not occur if
power is not removed from the ICAD prior to using the manual tool, and erroneous operation
will likely occur. Always remove power before using the manual tool, and restore power
afterward to ensure recalibration and trouble-free operation.
Service Parameters

The user will be able to troubleshoot and determine many of the conditions and set points
within the ICAD by accessing the Service Menu. A list of those service parameters follows
below:
Service Menu
Description

Display
Min.
name

Max. Unit Comments

OD %

50

100

AI [mA]

51

20

mA

Analog Input signal

AI [V]

52

10

Analog Input signal

AO [mA]

53

20

mA

DI

54

Digital Input signal

DO Close

55

Digital Output Closed status. ON when OD < 3 %

DO Open

56

Digital Output Open status. ON when OD > 97 %

DO Alarm

57

Digital Output alarm status. ON when an alarm is detected

MAS mP SW
ver.

58

100

Software version for MASTER Microprocessor

SLA mP SW ver.

59

100

Software version for SLAVE Microprocessor

ICM valve Opening Degree

Analog Output signal

It is also possible to restore the original factory settings to the ICAD by the following
procedure:
To restore factory settings:
1. Remove the power supply.
2. Activate down arrow and up arrow push buttons at the same time.
3. While holding the up and down arrow reconnect the power supply.
4. Release down arrow and up arrow push buttons.
5. When the display on ICAD is alternating between showing: CA and A1 the factory
resetting is complete.

10

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ICM/ICAD Motorized Valve

Installation, Programming, and Troubleshooting

Alarms

There are a number of alarms which are excellent indicators of improper installation or
set-up:
Description

Troubleshooting Tips

ICM
Comments
alarm text

No valve type selected

A1

At start-up A1 and CA will be displayed

Controller fault

A2

Internal fault inside electronics

Input error

A3

Not applicable if 01 = 2 or 02 = 2
When 03 = 1 and AI > 22 mA
When 03 = 2 and AI > 22 mA or AI < 2 mA
When 03 = 3 and AI >12 V
When 03 = 4 and AI >12 V or AI < 1 V

Low voltage of fail safe supply

A4

If 5 V d.c. < Fail safe supply

< 18 V d.c.

Check Supply to ICAD

A5

If supply voltage < 18 V d.c.

Problem

Possible cause and solution

The valve is not working and an A1 is

flashing in the display.

The ICM valve size was not selected in

parameter 26. See the programming
section on page 9.

The valve does not appear to be opening

or closing properly

1. The ICAD was not mounted properly

on the valve stem. Solution: Check to
make sure that the ICAD was mounted
evenly on the ICM valve
. The ICAD is not receiving a proper
input signal. Solution: Use the service
parameters (51 for a mA input or 52
for a voltage input) to check the input
signal that the ICAD is receiving.

The valve position feedback signal is not

working when using customer supplied
controller/PLC

1. A power supply was installed in the

4-20mA/0-20mA feedback loop.
The ICAD motor actuator supplies
the power for the 4-20mA/0-20mA
feedback loop. Solution: Remove any
power source that may be supplied to
the feedback loop.
. Wiring problem. Solution: Check the
service parameter 53 to see what the
ICAD is outputting. If this does not
reveal anything, check the current
output (yellow and blue wires in ICAD
control cable) with an ammeter.
3. The feedback output signal was turned
off in parameter 06. Solution: Check
to make sure the setting in parameter
06 is correct.

For all other problems, contact Danfoss.

Danfoss (USCO / MKS), 11 - 2006

DKRCI.EI.HT0.A1.22 / 520H1639

11

ICM/ICAD Motorized Valve

Installation, Programming, and Troubleshooting

Common Questions

What happens in the event of a power failure?

The ICAD will remain in the position it is in when power is lost. There are two ways to
address this condition:
Add a UPS (Uninterruptible Power Supply) to the power wiring. This is easily
accomplished with the green and white wires in the power cable. A UPS is
available from Danfoss. The UPS can provide service for up to 9 ICAD 600s or up
to 6 ICAD 900s.
Note: The UPS is not a continuous power supply. It is used to change the valve
position (usually to close the valve) in the event of a power failure. Therefore, the
system is not to be run in the UPS mode.
Add a solenoid valve in front of the ICM. This is a very simple solution provided
that there is no issue associated with the additional pressure drop through the
solenoid valve.
How much power do I need to supply to the ICAD?
The total power required depends on both the ICAD size and the number of ICADs powered
by the DC power supply. The power for each ICAD is:
For the ICAD 600 (used on ICM 20, 25, and 32), the power requirement is
approximately 30 W
For the ICAD 900 (used on ICM 40, 50, and 65), the power requirement is
approximately 50 W
How can I monitor the valve position remotely?
The control wiring provides for a 4 to 20 mA or 0 to 20 mA signal output (blue and yellow
wires). This signal can be sent to:
A remote display
A PLC or PC
Another ICAD motor to give the same opening position

Danfoss Refrigeration & Air-Conditioning Division 7941 Corporate Drive Baltimore, MD 21236
Ph 410-931-8250 Fax 410-931-8256 E-mail: baltimore@danfoss.com Internet: www.danfoss.com/North_America
12

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Danfoss (USCO / MKS), 11- 2006